Transport Case For Large Plasma/LCD/LED Flat Screen Displays And Other Like Items

ABSTRACT

A case for moving flat screen displays (plasma lcd and led), interactive white boards, digital signage and the like, comprising: a base and a mating lid; said base and said mating lid forming a fully enclosed storage compartment when fitted together; said base and said mating lid shaped to form a case that has a small depth compared to its height and width to create a storage compartment that is suitably shaped to accommodate a flat shaped item in a vertical orientation; said base having lateral ends that are wider in relation to the middle to create a stable base for the case; said base further comprising a cradle assembly to hold the item to be transported in cushioned suspension above the bottom surface of said base.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Patent ApplicationNo. 61/224,335, filed Jul. 9, 2009. All subject matter set forth inprovisional application No. 61/224,335 is hereby incorporated byreference into the present application as if fully set forth herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to transport containers for safely moving flatscreen display devices such as LCD, plasma, and LED flat displayscreens, interactive white boards, and like items that are large, flatshaped items which have sensitive surfaces that can easily be damaged ifnot well protected during transport from contact with surfaces insidethe case.

2. Description of the Related Art

Flat screen display devices such as liquid crystal display (LCD),plasma, and LED displays, interactive white boards, and the like havecreated a need for specialized transport containers to move these large,expensive items without damaging them. The screen surfaces aresusceptible to damage if they are bumped or rubbed. Thus, rentalcompanies, moving companies, conference centers, sound and videocontractors, and performance staging companies are all in need of alight weight, stable, reusable transport case that can fully protectthese delicate, flat shaped devices during transport.

U.S. Pat. No. 7,466,372 B2 to Kim discloses a transport case for theliquid crystal cells that are ultimately manufactured into a display,but this case is not designed to accommodate and protect a large endproduct display.

U.S. Pat. No. 7,140,508 to Kuhn discloses a flat shaped wooden shippingcase for valuables such as framed paintings. This wooden case has ashipping holder to secure the painting within the case, and furtherutilizes vacuum insulation panels to protect the contents from fire andextreme temperature changes. The shipping holder disclosed in thispatent encloses the entire perimeter of the painting. This case is notsuitable for moving delicate flat screen items because it is too heavy,it does not provide a means to keep the item oriented vertically up, andit does not have a means to protect packaging materials from rubbingagainst the delicate screen surface.

U.S. published application 20080272136 entitled Transport Case ForTransport Of High Value Heavy Transport Goods discloses a transport casedesigned to transport very heavy items, such as printers, that must beremoved from the case with a lift truck. It features a sliding objectcarrier at the base of the case that can move the item closer to theside of the case where the lift truck is situated. The lid of this casealso comprises the sides of the case when closed so that when the lid isremoved, there are no sides in the way of the lift truck when the caseis opened. This case is not useful for flat screen items because lifttrucks are not necessary for flat screen items, and the moving companiesand conference center industries do not wish to use lift trucks to moveflat screen items. Further, it does not incorporate the novel shape thatis ideal for stabilizing flat screen items in an upright orientation,and the design features that can protect a large screen area from beingtouched.

SUMMARY OF THE INVENTION

It is an object of the present invention to achieve a transport case formoving large, delicate, valuable flat screen items that is lightweightso it is manageable, and shaped to accommodate large, flat screen itemsand keep them in their vertical, upright position throughout the movingprocess.

It is further an object to achieve a case that protects the flat screenitem from the impact of any bumps by suspending the item in shockabsorbing cushion away from the rigid interior surfaces of the case.

It is further an object to achieve a case that protects the delicatescreen surface of the item to be moved from rubbing or contacting anycushioning, packaging, or assemblies designed to hold the item withinthe case.

It is further an object to achieve a case that incorporates rollers atthe base to further stabilize the case in an upright position and toprovide for easy movement of the large case.

It is further an object to incorporate useful handles to facilitate thelifting and moving of a large case and lid.

It is further an object to incorporate lid securing straps.

In one preferred embodiment, a transport case for moving large, flatscreen devices includes a base and a mating lid. The lid is configuredsuch that the lower portion slides over the corresponding top portion ofthe base to form a fully enclosed container. The base and lid are shapedsuch that the resultant case has a small depth compared to its heightand width (i.e. a flat screen shape), to accommodate large, flat screenitems. The case is wider at the lateral ends to provide a stable surfaceto keep the case in an upright orientation and prevent it from tippingover. The lower portion of the lid that overlaps with the top portion ofthe base at the widened lateral ends incorporates a horizontal shelfthat rests on the corresponding top vertical edge of the base to holdthe lid in suspension above the item to be transported. The wider basealso serves to accommodate the end supports of a cradle system thatkeeps the item to be transported in cushioned suspension away from theinterior sides of the case. The cradle system opening is adjustable toensure that various sized items can be securely held within the casewithout any part of the cradle holding assembly touching the delicateflat screen area of the item to be transported. The case is made oflightweight plastic that is reinforced to ensure the sides do notcollapse onto and touch the item inside without adding any appreciableweight to the case. Wheels, handles, and straps to secure the lid overthe base can be added for additional convenience and security.

BRIEF DESCRIPTION OF THE DRAWINGS

There are shown in the drawings certain exemplary embodiments of theinvention as presently preferred. It should be understood that theinvention is not limited to the embodiments disclosed as examples, andis capable of variation within the scope of the appended claims. In thedrawings,

FIG. 1 is an exploded perspective view of an embodiment of the presentinvention with the lid separated from the base,

FIG. 2 is a perspective view of an embodiment of the present inventionwith the lid closed over the base,

FIG. 3 is an exploded perspective view of an embodiment of the presentinvention showing the cradle assembly of the base,

FIG. 4 is an exploded perspective view of an embodiment of the presentinvention showing the reinforced channels of the base, and

FIG. 5 is a cross sectional front view of an embodiment of the presentinvention with the lid closed over the base.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-5, flat display transport cases according toembodiments of the present invention are now described.

FIG. 1 is an exploded view of an embodiment of the invention with thelid separated from the base. The case 1 comprises a base 2 and a matinglid 3. The base 2 has a bottom 4, an opening at the top 5, and aplurality of sides 6 extending upward from the bottom 4. The lid 3comprises a top 7, an opening at the bottom 8 (opening not visible), anda plurality of sides 9 extending downward from the top 7.

The base 2 and the lid 3 are cooperatively shaped, with the opening 8 atthe bottom of the lid 3 having a larger perimeter than the opening 5 atthe top of the base 2, so that the lid 3 can slide over the base 2 in anoverlapping fashion, creating a fully enclosed storage compartmentinside. FIG. 2 depicts an embodiment of the invention with the lid 3closed over the base 2. The lid 3 and the base 2 are cooperativelyshaped such that the overlapping portion of the lid 10 slides over thecorresponding top portion of the base 11 (hereinafter “nested portion ofthe base”), which is not visible in FIG. 2 because it is nested underthe overlapping portion of the lid 10.

The base 2 and lid 3 are sized and shaped to cooperatively form a case 1that accommodates a large, flat item in a vertical orientation. Thus, inthe top up orientation depicted in FIG. 1 and FIG. 2, the resulting casehas a relatively thin depth as compared to its height and width.

Referring to FIG. 1, it can be seen that the depth of the base widens atboth lateral ends 12 as compared to the middle 13. The overlappingportion of the lid 10 correspondingly widens at the lateral ends. Thisunique shape provides a stable base to prevent the case 1 from tippingover on its side. This unique shape simultaneously creates a horizontallid surface barrier 14 that prevents the lid 3 from resting on the topof the item to be transported. Thus, in the closed position, the lid 3is prevented from resting on the top of the item to be transported, andinstead, rests upon the vertical top edges of the base 35 thatcorrespond to the horizontal lid surface barriers 14. This unique shapealso perfectly accommodates the cradle assembly that is installed intothe interior bottom 4 of the base 2, described further herein.

The case 1 of the disclosed embodiments is fabricated of polyethyleneplastic that is rotationally molded as a single piece, and is thendivided into nested base 2 and overlapping lid 3 by cutting out a thin,transverse slice at the location that will become the mating edges ofthe base 2 and lid 3. Rotational molding is a process known in the artfor economically producing precision shaped plastic structures ofuniform thickness. It produces molded plastic that is approximately0.150 inches thick, resulting in a surprisingly light and manageablecase given its size. Using a single mold as opposed to two molds resultsin less wasted plastic.

Although thin molded plastic has the advantage of being light, durable,and low cost, it would not be ideal for fully protecting broad screenitems such as large plasma displays without some reinforcement. Thechallenge is providing the reinforcement without appreciably increasingthe overall weight of the case. Thus, in order to prevent the sides fromcollapsing in and possibly touching the delicate screen of the iteminside, the inventors herein devised a way to reinforce the broad sides17 of the front and back of the case (labeled on FIG. 2 and FIG. 4)without adding substantially to the weight of the case 1.

More specifically, in the disclosed embodiments, reinforcing channels 15are molded into the base 2 and lid 3 as shown in FIG. 1. The channels 15are designed to receive metal braces 16 (depicted in FIG. 4) that areriveted to the interior of the channel, or attached therein by anysuitable means. FIG. 4 is an exploded view that depicts an advantageousarrangement of reinforcing channels 15 for the base 2. This embodimentutilizes two channels 15 that wrap around the bottom 4 and receive thebraces 16 as depicted. This advantageous arrangement holds the centralportion of the broad sides of the base 17 rigidly away from the contentsof the case. No bracing is utilized at the lateral ends 12 of the base 2because the cradle assembly end supports 20 (discussed further herein)provide the needed reinforcement at the lateral ends 12.

Corresponding channels 15 are incorporated into the lid 3 as depicted inFIG. 1 and FIG. 2. Since the height of the lid 3 is not as great as theheight of the base 2, it is not necessary to wrap the channels aroundthe top of the lid 7 to prevent the middle sides 17 of the lid 3 fromcollapsing and touching the item within the case. Instead, the lid 3 ofFIG. 1 has an array of molded in ribs 18 to increase the rigidity of thetop without adding the weight of metal braces.

Aluminum is a useful brace material in that it is sufficiently rigid,yet light and resistant to corrosion. This novel process of utilizingthe strategic placement of reinforcement channels only where needed, incombination with other case structures, allows the case to remain verylight weight, yet rigid enough in critical locations to fully protectthe contents from contact.

Upon reading this disclosure, those skilled in the art may recognizeother suitable materials and possible channel arrangements for utilizinglightweight materials in conjunction with bracing channels to practicethe disclosed invention. The above disclosure is intended to fullydisclose the invention, including preferred embodiments, and is notintended to limit the scope of the claims to the exact materials orchannel layouts disclosed herein. The invention may be practiced withother suitable materials and may be practiced with or withoutreinforcing channels.

The base 2 further comprises a cradle assembly to hold the item to betransported in cushioned suspension above the interior of the bottom ofthe base 4. FIG. 3 is an exploded view of the base 2 that depicts acradle assembly in accordance with the present invention. The cradleassembly is comprised of two cushioned end supports 20, and two middlecushions 21. The end supports 20 are separately molded polyethyleneplastic in the disclosed embodiment. They are comprised of a bottom 22,and three sides 23. The top 24 and the fourth vertical side 25 are leftopen to receive and hold the item to be transported.

The end supports 20 are secured to the interior bottom and sides of thebase 2 (not fully depicted) by rivets or any other suitable means. Theinterior bottom 4 of the base 2 may be formed with protrusions (notdepicted) to guide the proper alignment of the end supports 20 onto theinterior bottom 4 of the base 2 during assembly. To provide a fullycushioned cradle, the disclosed end supports 20 can be interiorly linedon all surfaces (22 and 23) with a type of molded foam known in the artas closed cell polyethylene foam 26. The molded foam lining 26 can bepermanently adhered to the end supports with a pressure sensitiveadhesive that is known in the art to be suitable for this use.

Additional strips of adhesive backed molded foam 27 can be adhered tothe foam lining 26 to adjust the size of the end support opening(defined by the open top 24 and the open fourth vertical side 25). Theexploded view of FIG. 3 shows how wider strips 27 a can be used at thelateral ends to shorten the depth of the end support opening, andnarrower strips 27 b can used to adjust the width of the end supportopening at precisely selected locations to allow the foam 27 b to touchonly the frame of the item to be transported and not touch the delicatescreen area. These additional strips of foam 27 can either bepermanently attached, such as with pressure sensitive adhesive, or theycan be removably attached, such as with Velcro, to allow customadjustments to a single case 1 for a variety of flat screen items.

The two middle cushions 21 can be fabricated of the same foam in theshape depicted in FIG. 3. They can be permanently adhered to theinterior bottom 4 of the base 2, spaced in a roughly equidistant mannerbetween the two end supports 20. The middle cushions 21 are shaped tosupport the bottom edge of the item to be transported, and to work inunison with the end supports 20 to support the item to be transported incushioned suspension above the interior bottom 4 of the case. FIG. 5 isa cross sectional view of a closed case that depicts the cradle assemblyinstalled into the bottom of the base 4. This embodiment also includeslid foam cushions 28 on the interior of the top 7 of the lid 3.

It can be seen from FIG. 5 how the bottom of the item to be transported(item to be transported not depicted) would rest on horizontal foamsurfaces 26 and 21 in suspension above the rigid interior bottom of thebase 4. The vertical sides 23 (see FIG. 3) of the end supports 20 holdthe corresponding vertical sides of the item to be transported firmly inplace. The foam lining 26 of the vertical sides provides cushioning fromimpacts, and the custom foam strips 27 reduce the depth and width of theend support opening to snuggly hold the frame of the item to betransported without touching the delicate screen area. See also FIG. 1for a view of the tops of the end supports 20 with associated cushioning(26, 27 a, 27 b).

Those skilled in the art will recognize and appreciate that a cradleassembly in accordance with this invention can be fabricated ofdifferent materials and shapes. The detail provided above is intended toprovide a full and complete disclosure including preferred embodiments,and is not intended to limit the scope of the claims to the specificcradle assembly embodiments disclosed above.

To enhance the mobility of the case 1, rolling mechanisms 29 (labeled inFIG. 2) can be attached to the exterior bottom of the base 4 in anysuitable fashion known in the art. The disclosed embodiments utilizefour caster wheels 29 (three are visible), two at each lateral end. Thecasters 29 are bolted to the exterior bottom 4 of the base 2 in standardfashion. For enhanced directional control while moving the case 1, thedisclosed embodiments utilize two swiveling casters on one end (theforward end during movement), and two non-swiveling casters on the otherend.

The above arrangement of rolling mechanisms 29 are preferred forenhanced mobility and directional control, but those skilled in the artwill recognize that any suitable number, orientation, and type ofrolling mechanisms, or no rolling mechanisms at all, can be utilized topractice the invention.

The FIG. 2 embodiment includes two straps 30 to secure the lid 3 to thebase 2. The straps may be fabricated of heavy duty 1.5″ nylon web. Theycan be permanently secured to the front of the base at any suitablelocation (attachment point not shown), and wrap around the bottom of thebase 4 being securely buckled at the top of the lid 7 (buckles notdepicted). Camphered edges 31 as shown in FIG. 2 can be utilized toprevent gaps between the straps 30 and the exterior bottom of the base4. In the disclosed embodiment, the straps 30 completely encircle theclosed case 1. It should be appreciated that the invention can bepracticed without straps 30, or with any variety of lid securingarrangements or devices known in the art.

The case 1 of the present invention can be further equipped with avariety of handles. A useful arrangement is as depicted in FIG. 1 andFIG. 2. The lid 3 is equipped with two lift bars 32, one at each end, tofacilitate lifting the lid 3 on and off the base 2. The lift bars 32 canbe fabricated with annodized aluminum tubing, or any other suitablehandle type known in the art. A corresponding handle recess 33 is usefulto allow plenty of room for a hand to grasp the bar 32. The base 2 hastwo molded in end lift handles 34, one on each end, to facilitatelifting the base 2 either alone, or with the lid 3 installed as needed.(FIG. 5 depicts lift handles in cross sectional front view.)

It will be appreciated that many varieties and arrangements of handlescan be utilized within the scope of the invention, and that theinvention is not limited to any particular handle arrangements. Handlesare not necessary to practice the invention.

The closed case embodiment of FIG. 2 has the following approximatedimensions: 35 inches high, 54 inches wide, 16 inches deep at thewidened depth, and 10 inches deep elsewhere. These dimensions are usefulto accommodate the variety of sizes of large flat screen display devicesthat are prevalent in the market at the time of this application.

The above disclosure is intended to fully disclose the inventionincluding preferred embodiments. Modifications and variations of thepresent invention that would be obvious to a person of ordinary skill inthe art are deemed to be within the scope of the present invention. Forinstance, those skilled in the art will appreciate that the inventioncan be practiced with a variety of lid and base arrangements, and thenested arrangement that incorporates the shelf to hold the lid above theitem to be transported are not the only lid and base arrangements thatcan be used to practice the invention.

1. A case for moving flat screen displays (plasma lcd and led),interactive white boards, digital signage and the like, comprising: abase and a mating lid; said base and said mating lid forming a fullyenclosed storage compartment when fitted together; said base and saidmating lid shaped to form a case that has a small depth compared to itsheight and width to create a storage compartment that is suitably shapedto accommodate a flat shaped item in a vertical orientation; said basehaving lateral ends that are wider in relation to the middle to create astable base for the case; said base further comprising a cradle assemblyto hold the item to be transported in cushioned suspension above thebottom surface of said base.
 2. A case as set forth in claim 1, whereinsaid base and said lid fit together in a nested fashion with said lidhaving an opening sized to slide over the top of said base in anoverlapping fashion.
 3. A case as set forth in claim 2, wherein said lidhas an interior horizontal shelf that when fitted on said base rests onthe corresponding top vertical edge of said base to hold said lid insuspension above the item to be transported.
 4. A case as set forth inclaim 2, wherein said base and said lid are made of polyethylene thathas been rotationally molded as a single piece, and then divided intonesting base and lid by cutting out a transverse slice of the singlepiece at the location that will become the mating edges of the base andlid.
 5. A case as set forth in claim 1, wherein said base and said lidfurther comprise one or more reinforcement channels.
 6. A case as setforth in claim 2, wherein said base and said lid further comprise one ormore corresponding reinforcement channels.
 7. A case as set forth inclaim 1, wherein said cradle assembly includes cushioned supports ateach of said lateral ends of said base.
 8. A case as set forth in claim1, wherein said cushioned supports further comprise a plurality of selfadhering cushion strips to adjust the size of said cushioned supports tosnuggly grasp the edges of the item to be transported, and to allow saidcushion strips to be placed so as avoid contact with display surfaces.9. A case as set forth in claim 1, further comprising rolling mechanismson the bottom of said base.
 10. A case as set forth in claim 1, whereinsaid lid further comprises a plurality of ribs for increased rigidity.11. A case as set forth in claim 1, wherein the inside top of said lidfurther comprises cushioning to further protect the top portion of theitem to be transported.
 12. A case for moving flat screen displays(plasma lcd and led), interactive white boards, digital signage and thelike, comprising: a base and a mating lid; said base having a bottomwhich defines the bottom of the case, an opening at the top, and aplurality of sides extending upward; said lid having a top which definesthe top of the case, an opening at the bottom, and a plurality of sidesextending downward; said lid opening sized to slide over the top of saidbase in an overlapping fashion; said base and said lid beingcooperatively shaped such that when said lid is placed over top of saidbase, the top portion of said base is nested within the correspondingbottom portion of said lid forming a fully enclosed storage compartment;said lid and said base having sides that are substantially longer thanthe width of said top and said bottom of the case to create a storagecompartment that is suitably shaped to accommodate a flat shaped item ina vertical orientation; said base having lateral ends that are wider inrelation to the middle to create a stable base for the case; said lidhaving a lower portion of the lateral ends correspondingly widened outto cooperate with the width of said lateral ends of said base to createa horizontal lower lid shelf that rests upon the vertical top of saidbase thereby suspending the top of the lid above the top of the item tobe transported; said base further comprising a cradle assembly to holdthe item to be transported in cushioned suspension above the bottomsurface of the base; said base and said lid having correspondingreinforcement channels.
 13. A case as set forth in claim 12, whereinsaid base and said lid are made of polyethylene that has beenrotationally molded as a single piece, and then divided into nestingbase and lid by cutting out a transverse slice of the single piece atthe location that will become the mating edges of the base and lid. 14.A case as set forth in claim 12, wherein said cradle includes cushionedsupports at each of said lateral ends of said base.
 15. A case as setforth in claim 14, wherein said cushioned supports further comprise aplurality of self adhering cushion strips to adjust the size of saidcushioned supports to snuggly grasp the edges of the item to betransported, and to allow said cushion strips to be placed so as avoidcontact with display surfaces.
 16. A case as set forth in claim 12,wherein said case further comprises two or more straps permanentlyattached to said base for securing the lid onto said base.
 17. A case asset forth in claim 16, wherein said base has a chamfered edge for saidstraps to pass over at the location where the front and back base sidesmeet the base bottom.
 18. A case as set forth in claim 12, wherein saidbase further comprises rolling mechanisms attached to the bottom of saidbase to allow the case to be rolled.
 19. A case as set forth in claim 1,wherein said lid further comprises a plurality of ribs for increasedrigidity.
 20. A case as set forth in claim 1, wherein the inside top ofsaid lid further comprises cushioning to further protect the top portionof the item to be transported.